Light weight load bearing metal structural panel

ABSTRACT

A light weight load bearing metal structural panel is provided which is adapted to replace other forms of wall and partition studding or framing and to which suitable wall coverings are adapted to be secured such as wall board or other desirable sheathing materials, and the like. Prefabricated built-up panel units may utilize the metal structural panel units as body reinforcement for efficient load bearing utility such as in prefabricated walls, partitions, roof decking, floor decking, etc.

llnited States Patent [191 Nicosia Mar. 25, 1975 LIGHT WEIGHT LOADBEARING METAL STRUCTURAL PANEL [75] Inventor: Joseph A. Nicosia, RiverForest, 111.

[73] Assignee: Robert A. Pacenti, Berwyn, 111.

[22] Filed: May 7, 1973 [21] Appl. No.2 358,071

52/600, 52/615, 52/672 [51] int. Cl. E04c 5/04 [58] Field of Search52/672, 671, 670, 241,

[56] References Cited UNITED STATES PATENTS 1,128,659 2/1915 Clark52/672 1,299,425 4/1919 Carpenter.....

1,852,002 4/1932 Clark 52/352 X 2,076,472 4/1937 London 52/241 2,263,8141 H1941 Nicholson 52/672 X 2,448,109 8/1948 Michael a 52/364 2,582,1441/1952 Miles 52/404 2,663,181 12/1953 Collman 52/241 2,934,934 5/1960Berliner 52/601 3,108,406 10/1963 Ellis 52/670 X 3,562,985 2/1971Nicosia 52/241 FOREIGN PATENTS OR APPLICATIONS 16,187 1898 UnitedKingdom 52/670 Primary E.\'uminerAlfred C. Perham Attorney, Agent, orFirm-Hill, Gross, Simpson, Van Santen, Steadman, Chiara & Simpson [57]ABSTRACT A light weight load bearing metal structural panel is providedwhich is adapted to replace other forms of wall and partition studdingor framing and to which suitable wall coverings are adapted to besecured such as wall board or other desirable sheathing materials, andthe like. Prefabricated built-up panel units may utilize the metalstructural panel units as body reinforcement for efficient load bearingutility such as in prefabricated walls, partitions, roof decking, floordecking, etc.

12 Claims, 6 Drawing Figures LIGHT WEIGHT LOAD BEARING METAL STRUCTURALPANEL The present invention relates to improvements in structural panelunit structures, and is more particularly concerned with light weightunits of this type formed from sheet metal.

Numerous and varied forms and arrangements of reinforcement have beenprovided for prefabricated structural panels and other structural units.Such reinforcements have been useful only as reinforcement and have notbeen useable as studding or framing as such. In other words, it has beennecessary to incorporate the reinforcement in a built-up panel or otherstructural shape with other materials. Insofar as I am presentlyinformed, no one has heretofore provided a light weight load bearingmetal structural panel which is adapted either to serve as buildingframing or studding to receive any desired wall covering or sheathingthereon, or to serve as a body reinforcement'for a built-up orprefabricated panel. It is to the attainment of such a structure thatthe present invention is directed.

An important object of the invention is to provide a new and improvedlight weight structural panel unit formed from sheet metal and possessedof great compression strength and resistance to applied forces in itsplane as well as across its plane and which may serve by itself asbuilding wall framing or studding or may be embedded in a built-upprefabricated panel constructron.

Another object of the invention is to provide a low cost light weightstructural panel unit formed in part of expanded metal sections. 7

A further object of the invention is to provide a new and improved loadbearing sheet metal panel unit.

Still another object of the invention is to provide a new and improvedprefabricated panel unit having unique load sustaining bodyreinforcement.

Other objects, features and advantages of the invention will be readilyapparent from the following description of certain preferred embodimentsthereof, taken in conjunction with the accompanying drawing althoughvariations and modifications may be effected without departing from thespirit and scope of the novel concepts embodied in the disclosure, andin which:

FIG. 1 is an isometric fragmentary, exploded detail view showing arepresentative form of a light weight high compression strength loadbearing metal structural panel unit embodying features of the invention;

FIG. 2 is a fragmental isometric view showing one use of the panel unitof FIG. 1.

FIG. 3 is an enlarged fragmentary sectional detail view takensubstantially along the line III-III of FIG. 2.

FIG, 4 is a fragmentary isometric view showing a modification in thestructural panel unit.

FIG. 5 is a transverse sectional detail view showing another use for thepanel unit.

FIG. 6 is a fragmentary transverse sectional view showing still anotheruse for the structural panel unit.

In a representative form of light weight high compression strength loadbearing metal structural panel unit 10 embodying features of theinvention, as shown in FIG. 1, principal elements comprised spacedcoextensive generally U-shaped load bearing side channel bars 11provided with Web portions 12 defining side edges of the panel unit andhaving solid marginal substantial width bearing and nailing flanges 13extending inwardly of the unit at opposite face planes of the unit. Anopen mesh body connects certain of the flanges 13 of the side bars 11 inthe unit 10 and maintains the side bars in substantially fixed spacedrelation.

In the illustrated instance the unit 10 is of a width wherein a loadbearing intermediate bar 15 is desirably located midway between andcoextensive with the side bars 11. In one preferred construction, theintermediate bar 15 is of rugged channel beam structure comprising apair of spaced apart oppositely extending coplanar solid bearing andnailing flanges 17 to which respective sections 18 of the body 14 areconnected. The flanges 17 are substantially the same width as and lie ina face plane with those flanges 13 of the side bars 11 to which thesections 18 are also connected. Extending angularly from the flanges 17in spaced apart relation are side wall flanges 19 ofthe bar 15 whichjoin a connecting solid bearing and nailing web flange 20 desirably ofthe same width as and lying in a plane with the side bar flanges 13 atthe opposite face ofthe panel unit 10 from the flanges 17. It will thusbe apparent that the panel unit 10 comprises the rigid side bars 11 andthe rigid intermediate bar 15, all cooperating to provide an efficientload bearing structure in the plane thereof considered longitudinallywith respect to the bars 11 and 15 and wherein great resistance isprovided against not only compression but also tension loads transverseto the axes of the several bars of the unit.

Low cost, efficient construction of the panel unit 10 is enhanced bymaking the entire unit from a single sheet of suitable gauge metal andwith the body sections 18 of open mesh structure, preferably provided bythe expanded metal technique wherein staggered longitudinal slits aremade in the sheet metal in an area which is narrower than intended forthe completed panel, and the metal than stretched laterally to expandthe slits whereby a uniform pattern of mesh openings 21 and integralmutually interconnecting portions 22 are integrally connected to the barflanges 13 and 17. By preference, also, the side wall flanges 19 of theintermediate bar 15 are provided with respective expanded sections 23preferably extending throughout the length of these flanges 19. It willbe observed that substantial width portions of the side walls 19angularly joining the flanges 17 and the web 20 are solid andunexpanded, whereby longitudinal load bearing integrity of the bar 15 ispreserved. If preferred, although not shown, the web portions 12 of theside bars 11 may also be formed with expanded metal sections similarlyas the expanded metal sections 23.

In one desirable embodiment, the panel unit 10 may be adapted forbuilding wall or partition use, being generally conformed toconventional dimensions for that purpose thus, for example, the panelunit may be of an over-all width of four feet, with the flanges 13 ofthe side bars 11 of about 1 /2 inch width and 2 inch depth, with theintermediate bar 15 also of 2 inches depth and preferably about 4 /2inches in width, i.e. substantially three times the width of one of theflanges 13, as shown in FIGS. 1 and 5, between the edges of the flanges17 to which the expanded metal sections 18 are connected. Length of theunit may be as preferred for any particular requirement such as 8 or 10feet. Through this arrangement, a plurality of the units 10 can bemounted in upright coplanar relation edge to edge and provide framingfor a partition of a wall and conforming generally to a similarpartition of a wall framed out with wooden 2" X 4"s. For doorways orother openings, suitable gaps can be provided between panel units, andwith shorter panel units providing head closure framing above doorwaysand windows, and shorter panel portions also providing wall closureframing below the windows.

By way of example of use of the panel unit in a partition or wall, asrepresented in FIGS. 2 and 3, the length of the unit is such as to fitclosely between a floor 24 and a roof or ceiling 25. Attachment of thepanel to the floor is desirably effected through a horizontal base plate27 which is preferably in the form of a channel or L-shapedcross-section sheet metal bar having a web flange secured in anysuitable manner as by means of lag bolts, nails, or other fasteningmeans to the floor and providing one or more upwardly extendinglongitudinally running flanges to which the lower end portions of theside bars 11 and the intermediate bar are secured by any suitable meanssuch as spot welding, suitable clips, power driven fasteners, or thelike. At the ceiling, the unit 10 is secured as by means of a sheetmetal head runner strip 28 having a horizontal flat flange 29 secured inany suitable manner such as by nails, lag screws, and the like to theceiling and with a downwardly projecting flange 30 to which the upperend portions of the panel unit bars are secured as by means of spotwelding 31, power driven fasteners, or the like. If preferred, ofcourse, the channel runner member 27 may be applied to the ceiling tosecure the upper end of the panel unit and the I.- shaped member 28 maybe secured to the floor. Through this arrangement, after the U-shapedrunner member has been secured in place, the panel unit 10 can beinserted endwise therein and the unit then swung to position its otherend within the member 28 against the flange 30.

After framing of a partition or a wall has been completed by securingthe necessary number of the panel units 10 in place, suitable wallcovering can be applied to one or both faces of the panel units. Forexample on an inside wall, wall-board panels 32 can be applied to thefaces of the panel units 10 and secured thereto by means such as nails33 driven directly into the side bar flanges 13 as shown in FIG. 3, andalso secured by such nails 13 to the flanges 17 as indicated in FIG. 2,and also at the opposite face to the web flange 20 of the intermediatebar 15. Similarly, the wall covering panels 32 can be secured along withtheir upper and lower margins to the vertical flanges of the runnerplates or strips 27 and 28, if desired. For sound-proofing, fireresistance and insulation, batts 34 (FIGS. 2 and 3) of suitable materialsuch as fiberglass, rockwool, or the like, may be filled into the hollowspaces provided between the side bars 11 and the intermediate bar 15,and into the hollow space within the intermediate bar 15. At ei- ,theror both faces of the batt 34 a vapor barrier sheet 35 may be provided.

Where the panel units 10 provide'outside wall framing, it will bereadily apparent that instead of wallboard such as employed for insidewall and partition covering, exterior wall sheathing may be applied, andthen any preferred outside wall covering applied thereover as preferred.Where the panel units 10 serve as direct load bearing wall framing, theycan be erected on a base slab or floor and suitably propped similarly aswith conventional framing, and either the member 28 or the member 27applied as a cap plate on the upper end of one or more of the panelunits, and a superstructure such as a floor or roof then erected on topof the thus provided framing, with the cap plates providing the means towhich the super-structure is secured.

Instead of having the intermediate load carrying bar of a generallychannel beam form as is true of the bar 15 shown in FIG. 1, a generallyZ-shaped cross-section intermediate bar 37 (FIGS. 4 and 6) may beprovided in a panel unit 10 which in other respects may be substantiallythe same as the panel unit 10. In this instance, the intermediate bar 27has a web flange 38 extending between and maintaining a pair ofoppositely projecting coextensive solid flat flanges 39 in spacedrelation and at the opposite face planes of the unit 10. Ex-

panded metal sections 18' are integral with and extend diagonally fromthe distal edges of the flanges 39 to and are integral with the distaledges of the respective flanges 13 of the side bars 11' of the unitwhich lie in the other face plane of the unit 10 from that in which therespective flanges 39 lie. By preference, the web flange 38 is providedwith an open mesh, expanded metal section 40. As shown, the solidbearing and nailing flanges 13' and 39 are all of substantiallyidentical width. This Z-shaped formation of the intermediate bar 37 is,as will be apparent, a simpler formation than the intermediate bar 15,and for some purposes will be adequate from a load supportingconsideration, and for some reasons may be preferred.

In addition to its use as in wall and partition structures, the panelunit 10 or 10 may be used as planking or deck covering such as infloors, roofs, walkways in bridge structures and overpasses, balconies,and the like. By reason of load supporting capabilities of the variousbars in the units, they are capable of thoroughly withstanding not onlycompression but also tension loads applied there across from the facesof the unit. Hence, a roof or floor may be constructed by mounting theunits 10, 10 in generally horizontal fashion on suitable supportingstructure and then applying any suitable covering, i.e. roof covering,tread surface material, etc, to the upper face of the panels in the deckassembly. Where the structure is a roof, ceiling panels or sus pendedceiling may be applied to the undersurface of the erected panel unitsl0, 10'. On the other hand, the panel 10 or 10 if preferred, may becompletely embedded as structural reinforcement within a concrete slab41 (FIG. 5). In such an arrangement, the expanded metal body sections 18and the expanded metal sections 23 of the intermediate bar 15 as well asexpanded sections in the webs of the side bars 1] enable thoroughinterlocking of the panel section 10 within the concrete slab 41. Thisarrangement is especially suitable for use of light weight types ofconcrete, thereby gaining not only the advantages of the light weightreinforcement provided by the panel unit 10, but also the light weightcharacteristics of the concrete. Of course, if preferred, the panel unit10 may be utilized to provide the internal body reinforcement for theconcrete slab 41 and for some purposes may be preferred. One or bothfaces of the concrete slab 41 may be provided with a suitable sheathingor facing 42.

Efficient use may be made, as shown in FIG. 6, of the panel units of thepresent invention in prefabricated slabs such as may be filled withexpanded polyurethane 43 or other light weight body material for whichthe panel unit may serve as the principal load sustaining structure. Asshown the unit has been incorporated in the slab although the unit 10may be similarly employed. In such a slab, the core material 43 fillsthe panel unit between the end bars 11 of the panel unit, and flush withthe opposite face flanges l3 and 39. If preferred any suitable facingsheets 44 may be applied to either or both faces of the slab. Numerousand varied uses for such a slab will be readily envisioned, such asprefabricated wall or partition panels, roofpanels, floor panels, andthe like. Where used as wall or partition panels, the prefabricated slabof FIG. 6 may be substituted for the drywall construction as describedin connection with FIGS. 2 and 3.

It should be apparent that the present invention provides a versatilelight weight high compression and tensile strength load bearing metalstructural panel unit which is adapted to be made from light weightsteel, aluminum, or other light sheet metal of suitable gauge to meetparticular load requirements Maximum utility of material is provided forin the one piece thoroughly reinforced expanded metal body constructionwith the efficient load carrying flanged bar structures providingexcellent compression load resistance not only longitudinally thereofbut also transversely thereof, and in addition excellent tension loadresistance transversely thereof. Manufacture of the panel units can beeconomically effected by utilizing coiled sheet metal stock slitaccording to expanded metal techniques in those areas to be expanded andshaped in those areas which provide the bars, utilizing metal expandingtechniques and shaping rolls in continuous stream production. Thefinished metal panel units are provided with integral load bearingcolumn or beam bars integrally connected in the preferred dimensionalrelationships for unit handling and erection such as in walls,partitions, roofs, floors, walkways, patios and the like.

It will be understood that variations and modifications may be effectedwithout departing from the spirit and scope of the novel concepts ofthis invention.

I claim as my invention:

1. A light weight high strength compression and tension load sustainingstructural panel unit formed from sheet metal and especially suitable tobe fabricated in 4 feet width by 8 to 10 feet length and 2 inchesthickness, comprising:

spaced coextensive generally U-shaped load supporting side channel barsprovided with web portions defining side edges of the panel unit andeach bar having two solid marginal flanges extending inwardly of theunit and lying in respective parallel opposite face planes of the unitand providing bearing and nailing surfaces of substantial and aboutequal width;

a single intermediate load carrying bar of rugged channel beammulti-flange cross section coextensive with and substantially spacedfrom and midway between said side bars and being of no greater thanabout three times the width of said side bar marginal flanges;

said intermediate bar having:

a pair of spaced apart oppositely extending coplanar solid bearing andnailing surface flanges, the distances between the remote edges of saidpair of flanges being about three times the width of one of saidmarginal flanges, and said pair of flanges lying in one of said faceplanes of the unit and coplanar with the marginal flanges in said oneface plane;

a solid bearing and nailing surface web flange at least as wide as oneof said marginal flanges lying in the other of said face planes andcoplanar with the marginal flanges in said other face plane; and

respective angularly extending side wall flanges rigidly connecting andspacing the adjacent edges of said web flange and the proximal edges ofthe pair of flanges; and open mesh body portions of the unit connectingthe marginal flanges of said side bars in said one face plane with therespective distal edges of the adjacent ones of said pair of flanges ofsaid intermediate bar and thereby maintaining the side bars and theintermediate bar in substantially fixed spaced relation.

2. A panel unit according to claim 1, wherein said sidewall flanges areof open mesh structure.

3. A panel unit according to claim 2, wherein said bars and said bodyportions are all formed from one piece of sheet metal and said open meshbody portions and said open mesh sidewall flanges comprising expandedmetal sections.

4. A panel unit according to claim 1 wherein the web portion of saidside bars are expanded metal sections between said marginal flanges.

5. A panel unit according to claim 1, wherein the webs of said side barsare expanded metal sections between said marginal flanges, and saidintermediate bar has an expanded metal section in each side wall flange.

6. A structural panel according to claim 1, mounted vertically in and aspart of a wall, wall board applied to at least a selected one of saidface planes, and nails secured through the wall board and through theflanges of the side bars and the intermediate bar flange or flanges insaid selected face plane and thereby securing the wall board panel tothe unit at said selected face plane.

7. A panel unit according to claim 1, wherein the side wall flanges ofsaid intermediate bar have expanded metal sections, and a body of lightweight material molded in said unit between said side bars and havingsaid side wall flanges embedded therein.

8. A panel unit according to claim 7, including vapor barrier sheetmeans interposed between said body and said marginal flanges and saidintermediate bar flanges lying in said one face plane of the unit andsaid open mesh body portions.

9. A light weight high strength compression and tension load sustainingstructural panel unit formed from sheet metal and especially suitable tobe fabricated in 4 feet width by 8 to l0 feet length and 2 inchesthickness, comprising:

spaced coextensive generally U-shaped load supporting side channel barsprovided with web portions defining side edges of the panel unit andeach bar having two solid marginal flanges extending inwardly of theunit and lying in respective parallel opposite face planes of the unitand providing bearing and nailing surfaces of substantial and aboutequal width;

a single intermediate load carrying bar of rugged generally Z shapemulti-flange cross section coextensive with and substantially spacedfrom and midway between said side bars and being of about two times thewidth of said marginal flanges and having:

a solid bearing and nailing surface flange in one of said face planeslying coplanar with and of substantially the same width as one of themarginal flanges in said one face plane;

another bearing and nailing surface flange in the other of said faceplanes lying coplanar with and of substantially the same width as one ofthe marginal flanges which are in said other face plane; and

an angular connecting and spacer web flange rigidly integrally connectedto and between proximal edges of said bearing and nailing surfaceflanges of the intermediate bar;

an open mesh body portion of the unit extending diagonally between andintegral with the distal edge of the marginal flange at said one faceplane and the distal edge of the intermediate bar flange of the otherface plane; and

an open mesh body portion of the unit extending diagonally between andintegral with the distal edge of the intermediate bar flange at said oneface plane and the distal edge of the marginal flange at said other faceplane.

10. A panel unit according to claim 9, wherein said Z bar has the webflange of open mesh structure.

11. A panel unit according to claim 9, wherein said bars and said bodyportions are all formed from one piece of sheet metal and said bodyportions comprise expanded metal sections 12. A panel unit according toclaim 9, wherein the web flange is of open mesh structure, and a slabbody of light weight material molded within the panel unit between andwithin said side bars and having said web

1. A light weight high strength compression and tension load sustainingstructural panel unit formed from sheet metal and especially suitable tobe fabricated in 4 feet width by 8 to 10 feet length and 2 inchesthickness, comprising: spaced coextensive generally U-shaped loadsupporting side channel bars provided with web portions defining sideedges of the panel unit and each bar having two solid marginal flangesextending inwardly of the unit and lying in respective parallel oppositeface planes of the unit and providing bearing and nailing surfaces ofsubstantial and about equal width; a single intermediate load carryingbar of rugged channel beam multi-flange cross section coextensive withand substantially spaced from and midway between said side bars andbeing of no greater than about three times the width of said side barmarginal flanges; said intermediate bar having: a pair of spaced apartoppositely extending coplanar solid bearing and nailing surface flanges,the distances between the remote edges of said pair of flanges beingabout three times the width of one of said marginal flanges, and saidpair of flanges lying in one of said face planes of the unit andcoplanar with the marginal flanges in said one face plane; a solidbearing and nailing surface web flange at least as wide as one of saidmarginal flanges lying in the other of said face planes and coplanarwith the marginal flanges in said other face plane; and respectiveangularly extending side wall flanges rigidly connecting and spacing theadjacent edges of said web flange and the proximal edges of the pair offlanges; and open mesh body portions of the unit connecting the marginalflanges of said side bars in said one face plane with the respectivedistal edges of the adjacent ones of said pair of flanges of saidintermediate bar and thereby maintaining the side bars and theintermediate bar in substantially fixed spaced relation.
 2. A panel unitaccording to claim 1, wherein said sidewall flanges are of open meshstructure.
 3. A panel unit according to claim 2, wherein said bars andsaid body portions are all formed from one piece of sheet metal and saidopen mesh body portions and said open mesh sidewall flanges comprisingexpanded metal sections.
 4. A panel unit according to claim 1 whereinthe web portion of said side bars are exPanded metal sections betweensaid marginal flanges.
 5. A panel unit according to claim 1, wherein thewebs of said side bars are expanded metal sections between said marginalflanges, and said intermediate bar has an expanded metal section in eachside wall flange.
 6. A structural panel according to claim 1, mountedvertically in and as part of a wall, wall board applied to at least aselected one of said face planes, and nails secured through the wallboard and through the flanges of the side bars and the intermediate barflange or flanges in said selected face plane and thereby securing thewall board panel to the unit at said selected face plane.
 7. A panelunit according to claim 1, wherein the side wall flanges of saidintermediate bar have expanded metal sections, and a body of lightweight material molded in said unit between said side bars and havingsaid side wall flanges embedded therein.
 8. A panel unit according toclaim 7, including vapor barrier sheet means interposed between saidbody and said marginal flanges and said intermediate bar flanges lyingin said one face plane of the unit and said open mesh body portions. 9.A light weight high strength compression and tension load sustainingstructural panel unit formed from sheet metal and especially suitable tobe fabricated in 4 feet width by 8 to 10 feet length and 2 inchesthickness, comprising: spaced coextensive generally U-shaped loadsupporting side channel bars provided with web portions defining sideedges of the panel unit and each bar having two solid marginal flangesextending inwardly of the unit and lying in respective parallel oppositeface planes of the unit and providing bearing and nailing surfaces ofsubstantial and about equal width; a single intermediate load carryingbar of rugged generally Z shape multi-flange cross section coextensivewith and substantially spaced from and midway between said side bars andbeing of about two times the width of said marginal flanges and having:a solid bearing and nailing surface flange in one of said face planeslying coplanar with and of substantially the same width as one of themarginal flanges in said one face plane; another bearing and nailingsurface flange in the other of said face planes lying coplanar with andof substantially the same width as one of the marginal flanges which arein said other face plane; and an angular connecting and spacer webflange rigidly integrally connected to and between proximal edges ofsaid bearing and nailing surface flanges of the intermediate bar; anopen mesh body portion of the unit extending diagonally between andintegral with the distal edge of the marginal flange at said one faceplane and the distal edge of the intermediate bar flange of the otherface plane; and an open mesh body portion of the unit extendingdiagonally between and integral with the distal edge of the intermediatebar flange at said one face plane and the distal edge of the marginalflange at said other face plane.
 10. A panel unit according to claim 9,wherein said Z bar has the web flange of open mesh structure.
 11. Apanel unit according to claim 9, wherein said bars and said bodyportions are all formed from one piece of sheet metal and said bodyportions comprise expanded metal sections.
 12. A panel unit according toclaim 9, wherein the web flange is of open mesh structure, and a slabbody of light weight material molded within the panel unit between andwithin said side bars and having said web flange embedded therein.